installation instruction robinson - aveo engineering installati… · ave-wpsr-64g ave-wpsg-64g...

Installation Instruction

Robinson R22, R44 and R66 SERIES www.aveoengineering.com

ROBINSON Installation Instructions AVE-MOD-001-INS

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__________________________________________________________________________________ Aveo Engineering Group, s.r.o.

Drasov 202, 261 01 Drasov Czech Republic

Issue of form 01

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Part 0 Manual Administration 0.1 Table of Contents

PART 0 MANUAL ADMINISTRATION 2

0.1 TABLE OF CONTENTS 2

0.2 DOCUMENT APPROVAL 3

0.3 AMENDMENT RECORD PROCEDURE 3

0.4 EFFECTED PAGES PROCEDURE 4

0.5 DISTRIBUTION LIST 4

PART 1 INSTALLATION INSTRUCTION 5

1.1 GENERAL 5

1.2 CONTINUED AIRWORTHINESS 5

1.3 DESCRIPTION 6

1.3.1 Position and anti-collision lights 6 1.3.2 Taxi- and landing lights 6

1.4 LANDING LIGHT INSTALLATION FORWARD 7

1.5 LANDING LIGHT INSTALLATION AFT 9

1.6 NAVIGATION LIGHTS INSTALLATION – LEFT AND RIGHT 11

1.7 NAVIGATION LIGHTS INSTALLATION – TAIL POSITION 13

1.8 ANTI-COLLISION LIGHT INSTALLATION 15

1.9 ADDITION OF STROBE FUNCTION (NOT R66) 19

PART 2 COMPLIANCE DEMONSTRATION 21


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0.2 Document approval This document has been established in accordance with an alternative procedure to DOA approved under EASA AP429. This installation Instruction is applicable for Robinson helicopter R22, R22alpha, R22 Beta, R22 Mariner, R44, R44 II and R66 series.

Compiled by: 15. – Nov. - 2016 Peter Nezval

Engineer, Aveo Engineering Group, s.r.o.

Approved by: 15. – Nov. - 2016 Georg Hartl

Head of DO, Aveo Engineering Group, s.r.o.

0.3 Amendment Record procedure The master copy of this document shall be kept electronically as a read only document under the control of Aveo Engineering Group, s.r.o. as Master Copy. ALL amendments to this manual will initiate a raise of Issue ALL raises of issue will be given a sequential Alphabetic Issue Ident sequentially from 01 to 99 in Table 01 - Issue No: Column– Initial Issue of Document will be “01” ALL Issues of this document will be approved by Head of DO

Issue No. Details Date Effected

Pages 01 Initial Issue 25.May

2016 ALL

02

Addition of R22, R44a and R66 Addition of corrosion note

Anticollision light option B limited to 28V systems

Addition option C removal power supply Part 2 added to document (not marked)

19.Sep. 2016

Several as marked

16

20

03

Change R44a to R44 II and missing R22 models Change DL issue

Add option C for attachment anticollision light Change wiring diagram

15.Nov.2016

3 & 18 5 17 18

Table 01: Document Amendment Record Table


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0.4 Effected Pages Procedure ALL pages affected by ANY raise of issue of this manual will be listed in Table 01 - Effected Pages Column. The reason(s) for ALL raise of issue and description of change due to raise of issue will be provided for ALL raises of issue in Table 01 - Details Column. Changes from the previous issue are highlighted by YELLOW HIGHLIGHTING over new content. AND YELLOW HIGHLIGHTING AND CROSSING OUT of deleted content. Example (CROSSING OUT)

0.5 Distribution List As stated in 0.3 above; the master copy of this document shall be kept electronically as a read only document under the control of Aveo Engineering Group, s.r.o. as Master Copy. All holders of copies of this Document will be recorded by listing in Table 02 – Distribution List. Copy holders listed will be issued a copy of this document with sequential copy number as shown in Table 02 – Distribution List

Copy No. Holder MASTER Aveo Engineering Group, s.r.o.

Table 02: Distribution List


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Part 1 Installation Instruction 1.1 General

This installation is to be performed in accordance to common practice as described in FAR AC 43.13-2B Chapter 4 and in FAR AC 43.13 1B Chapter 11 Section 15 (Bonding) as published by FAA. The installer is responsible to follow the installation instructions in the latest revision of:

• FAR AC 43.13-2B Chapter 4 • FAR AC 43.13 1B Chapter 11 Section 15 • AVE-H30-001-IM • AVE-WPS-64G-IM • AVE-POSW-54G-IM • AVE-RBXP-001-IM • AVE-RBCRW-001-IM

All drawings applicable for this change are listed in the Drawing List:

• AVE-MOD-001-DL, issue 02

The change is to be performed using the document AVE-MOD-001-MCS in the latest issue.

The aircraft modified according to this instruction may not be released back to service without the EASA design approval certificate being provided.

1.2 Continued Airworthiness The aircraft manuals remain fully valid. The inspection intervals and the procedures of the aircraft override the general statements in the component manuals as listed under §1.1.

For inspection of the new lights themselves follow the procedure of the Aveo Installation Manuals referenced above.


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1.3 Description This modification is the replacement of position, anti-collision, taxi- and landing lights by LED type lights.

1.3.1 Position and anti-collision lights The new position lights all also include the strobe function. Also two options for the anti-collision lights can be installed. The RedBaron XP Galactica offers only the red anti-collision light while the RedBaron combo HISL can be operated either as red beacon or white strobes. As not all R22, R44 and R66 helicopter are already equipped with the strobe function (white strobe) in addition to the red beacon, this function may be added with this modification. Hence the following optional installations can be done with this modification: For helicopter with strobe function already installed:

• Position lights including strobe + Beacon red (RedBaron XP) • Position lights including strobe + Beacon red including strobe (RedBaron HISL)

For helicopter without strobe:

• Position lights without strobe + Beacon red (RedBaron XP) • Additional switch and wiring change + Position lights including strobe + Beacon

red (RedBaron XP) • Additional switch and wiring change + Position lights including strobe + Beacon

red including strobe (RedBaron HISL) Synchronization: The position lights and the RedBaron HISL may be synchronized but the frequency of the strobes is so low that synchronization of the lights is not required. For the synchronization function the blue wires of each light to be synchronized have to be connected. If for this function additional wires are to be installed then these must be installed along the wire bundle in which the lights power wires run. If the function is not used the blue wire at each light is to be capped and stowed.

1.3.2 Taxi- and landing lights The R22, R44 and R66 is basically equipped with a taxi light (wide angle lens) and a landing light (narrow angle) in the forward belly fairing. Some helicopter have two landing lights (narrow angle) instead of the combination taxi-/landing light and some helicopter are additionally equipped with two landing lights near the aft landing gear attachment. This modification allows replacing all four lights with the same configuration as it is installed. A configuration change is not allowed.


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1.4 Landing Light Installation forward


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FIGURE AND

INDEX NUMBER

PART NUMBER DESCRIPTION PARTS AVAIL

QTY PER

ASSY

LANDING LIGHTS INSTALLATION

Option A 1 AVE-H30TATSNL-T0A Hercules Drop-In Landing 2 Option B

1 AVE-H30TATSNL-T0A Hercules Drop-In Landing 1 2 AVE-H30TATSNT-T0A Hercules Drop-In Taxi 1

NOTES Remarks:

1. It is to be checked by the installer before the modification whether Option A or B is installed on the aircraft. For a change in configuration e.g. 2 landing lights into 1 landing and 1 taxi light requires an additional EASA change.

2. Inspect the installation area for corrosion and correct according to AMM if required

3. Remove existing connector and replace as indicated. Verify polarity of wires before connection (ref. to AVE-H30-001-IM).


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1.5 Landing Light Installation aft


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FIGURE AND INDEX NUMBER


QTY PER

ASSY

LANDING LIGHT INSTALLATION

1 AVE-H30-W-002 Hercules LLP 2 2 1M.302.XLCT Connector LEMO FGN.1M.302.XLCT 2

3 AVS-WAU1451DLES-U0A Washer #1/4 Lock With External Tooth Thickness .030”

2

4 AVS-SCC0844HAS-C0A Screw #1/4-20 x 1-3/4" UNC HHCS 2

NOTES

Remarks:

1. Inspect the installation area for corrosion and correct according to AMM if required

2. Adjust light along flight direction (+/- 5°) 3. Item 4 is to be installed using bolt adhesive Loctite 2400. 4. Install connector delivered with light to the A/C wiring (ref. to AVE-H30-001-

IM).


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1.6 Navigation Lights Installation – Left and Right


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QTY PER

ASSY NAVIGATION LIGHTS INSTALLATION –

RIGHT AND LEFT POSITION

1 AVS-P000100175-A60 Ultra Adapter M5 2 2 AVS-WAU0612ESS-U0A Washer #6 Split Lock 6 3 AVS-SCC0510CAS-C0A Screw #6-32 x 3/8" SHCS 6

4 AVE-WPSR-64G AVE-WPSG-64G

Ultra Galactica Embedded Red Ultra Galactica Embedded Green

1

5 AVS-P000102114-A30 Mounting Screw M5 x 40 2 6 AVS-P001290550-A1A Gasket 2

NOTES

Remarks: Inspect the installation area for corrosion and correct according to AMM if required

If the aircraft is not already equipped with the strobe function this function can be installed through this change by following the instructions in § 1.7. The lights are to be connected as described in manual AVE-WPS-64G-IM.

If the strobe function is not used the blue and the yellow wires described in the component installation manual are not used and therefore have to be capped and stowed.


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1.7 Navigation Lights Installation – Tail Position


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QTY PER

ASSY NAVIGATION LIGHTS INSTALLATION –

TAIL POSITION

1 AVE-POSW-54G PosiStrobe CP 1 2 AVS-P000100157-A6A PosiStrobe Adapter 1 3 AVS-WAU0611CSS-U0A Washer #4 Split Lock 2 4 AVS-SCC0313BPS-C0A Screw #4-40 x 1/2" BHCS 2 5 AVS-SCC0315FAS-C0A Screw #4-40 x 19/32" FHSCS 2 6

AVS- P000103402-A1A Gasket 1

NOTES


If the aircraft is not already equipped with the strobe function this function can be installed through this change by following the instructions in § 1.7. The lights are to be connected as described in manual AVE-POSW-54G-IM.



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1.8 Anti-Collision Light Installation

1

2

1

1

3

4

1

2

3

4

5

6

5

1

1

2

1

3 4 5

6


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D 1

2

3

4


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QTY PER

ASSY

ANTI-COLLISION LIGHT INSTALLATION

A Option A 1 AVS-P000102111-A3A Hex Socket Metric Screw Assy 1 2 AVE-RBXPR-001 RedBaron XP Galactica 1 3 AVS- OR05302N70-D0A O-ring 1 4 AVS- P000600099-A60 RB XP-HISL ADAPTER Adapter 1 6 AVS-P000100878-A10 Gasket 1 7 19-250094-000 WRM-25, Ring Clamp 1

B Option B

(28V system only) 1 AVE-RBCWR-001 RedBaron Combo HISL 1 2 AVS-SCM04008HAS-D0A Screw 4 3 AVS- P000600099-A60 RB XP-HISL ADAPTER 1 4 AVS-P000100878-A10 Gasket 1 5 19-250094-000 WRM-25, Ring Clamp 1

C

Option C (28V system only)

1 AVE-RBCWR-001 RedBaron Combo HISL 1

2 MS35206-234 Original Fasteners 4

3 MS35206-227 Original Fasteners 1

4 NAS620-6L Original Washer 1

5 B260-2 Terminal 1

6 MS35489-15 Original Grommet 1

D

Option D* (R22, R44 only)

REMOVING POWER SUPPLY BOX

1 A708-1* Strobe Power Supply 1 2 MS27039C0806* Screw 4 3 NAS1149FN816P* Washer 4 4 MS21042L08* Nut 4

NOTES * For earlier R22, R44s.


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Option B and C can be used on aircraft with 28V system only!

Option D: Earlier versions have a separate power supply for the anti-collision light. In this case the power supply must be removed. The connectors are to be removed and wires spliced according to standard practice:

• Wire 106 connected to red wire

• Wire 136 (GND) connected to black wire

• Clear wire to be capped and stowed

If the aircraft is not already equipped with the strobe function this function can be installed through this change by following the instructions in § 1.8. The lights are to be connected as described in manuals AVE-RBXP-001-IM or AVE-RBCRW-001-IM depending on which option is to be installed.



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1.9 Addition of strobe function (not R66) For helicopter which are not already equipped with the strobe function this function can be integrated using the following modification instruction. All R66 are already equipped with the strobe function and so this section is applicable only for R22 (all models), R44 II and R44.

Wiring Diagram

1

Newly installed wiring (Existing STROBE switch)

(Newly installed switch item 1) STROBE WHITE

(YELLOW) (YELLOW)

(YELLOW)

(RED)

NOTE: FOR INSTALLATION OF LIGHTS REFER TO MANUALS ACCORDING TO § 1

106

OFF

ON


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QTY PER

ASSY

STROBE FUNCTION INSTALLATION

1 AVS-PSHDP25S332-000 NKK Switch S332 1 64/65 AVS-P-000600040-000 Existing Base Panel (Modification)

NOTES

Remarks: To install the strobe light function:

1. Loosen the existing base panel as per maintenance manual chapter 8 and secure it.

2. Modify base panel according to drawing 0600040 and mark modified part with defined placard.

3. Take care that all sharp edges are removed and no scarf can remain on the A/C. 4. Install NKK Switch S332 (item 1) into the modified base panel (P/N AVS-

P000600040-000. The switch is to be labeled “OFF” and “Strobe White” to show the strobe mode.

5. Install the base panel according to Maintenance manual chapter 8. 6. Wiring is to be performed according the wiring diagram. If the strobes are to be

synchronized then the blue wires of the position lights and the anti-collision light must be connected. If the lights shall not be synchronized the blue wires of the different lights are to be capped and stowed. The additional wires are to be installed along the wire bundle with the wires for the position and anticollision lights.


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Part 2 Compliance demonstration This document is in relation to the certification program AVE-STC-001-PFC. The compliance is demonstrated for the following certification specification: Requirements MoC Statement of Compliance

CS 27.609 Protection of structure

MoC 0 (a) All parts installed are verified to be suitable. The installation instruction requests the aircraft structure to be inspected for probable corrosion before installing the new lights. (b) Not applicable

CS 27.1301 Function and installation

MoC 0 (a) All navigation and anti-collision lights are ETSO certified. All landing lights are qualified according to RTCA DO160 as per AVE-H30-001-CCL. (b) Only one optional switch may be installed an label is defined herein. (c) All equipment is installed within their limits.

CS 27.1383 Taxi and landing lights

MoC 0 (a)The configuration of the original installation is not changed. (b) is not affected as the installation is not changed. (c) is improved as the new lights are brighter than the originally installed. (d) The landing light surface temperature is significantly lowered by this modification.

CS 27.1529 Instructions for Continued Airworthiness

MoC 0 The modification does not require any changes to the aircraft maintenance procedure which is clearly stated in §1.1 General.

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